Abrasive article and method of making same



July 8, 1941.. R. P. CARLTON ETAL 2,248,853 ABRASIVE ARTICLE AND METHOD 0F MAKING SAME original Filed June 1, 193s 5 sheets-sheet 1 i.. m/w

.July 8, 1941. R. P. CARLTON rf-Au.'y

ABRASIVE ARTICLE AND METHOD 0F MAKING SAME Original Filed June 1, 19:33 5 Sheets-Sheet 2 July-8, 1941. R. P. CARLTON rs1-Al. 2248353' ABRASIVE ARTICLE AND METHOD MAKING SAME 1- briginal Filed June 1, 19:53

'5 sheets-Sinaai` s v July 8,194.1. R. P. cAnLfoN'mL 2.248.853."

` ABRAsIvE ARTICLE AND METHoD oF MAKING SAME original `Filed June 1, 1933 5 sheets-shea 4 MM fw( July-A8, 1941. R, P, `;";,1\R| T0r\1 ETAL 1 A 2.248.853.

ABRASIVE ARTICLE AND METHOD 0F MAKING SAME Orignalf Filedy June 1, 1933 5 Sheets-Sheet 5 Patented' July 8,` 1941 ABRAsIv. ARTICLE Mimmo AND METHOD F SAME v Richard Paul Carlton and Theodore Joseph Miller, St. lauL'Minn., assignorsV to Minnesota Mining Manufacturing Company, St. Paul,

Minn., a corporation of Delaware originel eplineenen June 1, 1933, serial No,

Divided `and this application June 3,

1940, Serial No. 338,612

Thisinvention relates broadly to' coating and coating materials especially'in sheet form, such asin the manufacture ofabra'sives, and the present invention among other'things nds utility in one of itsphase's in the .manufacture of abrasive wheels or discs, and while the invention in one of its forms is illustrated as adapted for coating and forming an abrasive disc, it will be under-r stood that certain other phases of theA invention are of quite general application Aand may be adapted for other purposes, such, for example, as a method of coating roong material with pulveruient mineral..

This application is a division of our co-pending application, Serial No. 673,886 led June1, 1933.

This invention, as will hereinafter appear, finds especial utility in the production of grinding discs wherein the abrading'surface is on a side thereof rather than on the periphery; and the 'invention also iinds utility in coating roong material so `that particles of' mineral deposited thereon are caused to lie flat, that is to say, with their major dimensions substantially parallel with the surface of the backing.

The customary procedure generally resorted to in the manufacture of abrasive wheels, discs and, the like generally includes the mixing of an abrasive grit, such as' aluminum oxide, silicon carbide or emery, with a suitable bonding material and then placing the mixture in a mold. The iinal setting up oi the bonding material is then eected by curing at a suiiicient temperature to the grit therein.

3 Claims. (Cl. 51-298) the abrasive wheel or disc' structure, more or lessf porosity or voids 'in the wheel acting as clearances for the material being abraded be pro- .vided lso/that fast and continuous cutting,` together with reduction in temperature of the wheel when engaging the work, should be attained. In obtaining these desiderata it is found that the porosity of the wheellin the caseof a molded structure tends to weaken the disc or" wheel and, due to the porosity, the structure' does nothave sufficient bond to rmly anchor The principal objects and advantages of the present invention reside in the provision of -an' improved method of manufacturing an abrasive Wheel, disc or the like having characteristics inY itsstructure which increase the cuttingability,

, strengthr` and durability ofthe device; the procause the bond to `flow and take a rm grip of the abrasive grit.' Several diiierent, forms of the adhesive or bonding material arel used, the

more common being that known as a vitrified or ceramic bond. In making such a wheel'it is `necessary to nre the wheel, that is to say, subject the mixture ef benaingmateriai and crit 'te a sumciently high, temperature to cause the bond' ing material to 'owrand thus, in efiect,'form a -porcelain bond between the various 'particles of vision ofl an improved method of manufacturing' an abrasive article such as a wheel or disc for abrading purposes, in' whic the cost of` manuacture. is considerably reduc d, with the attendant accomplishment of the desired control o! u ratio of bond,- that is to say, adhesive, vto the mineral or grit, and` to provide such an improved method in which the same may be carriedout 'as a substantially continuous process, thus simplifying the manufacture and reducing the ultimate costs; fthe provision oran iniproved .method of manufacturing abrasive wheels and discs in which a fabric suchas paper,-cloth or the like may be employed as a lcarrierforthe bond and grit and in which the ultimate size of the abrading wheel or disc'may be determined easily and by a sub-- stantiallyfcontinuous method; the provision of an improved i'orm of abrading wheel or disc wherein a controlled porosity o'f thestructure is obtained and wherein the ratio of adhesive material to grit isfsubstantially uniform throughout the entire wheel or disc; lthe provision of an improved abrasive article such as a wheel or disc wherein the grit particles are oriented so that grit. Obviously, such a wheel or disc is inflexible,

broadly, and will not standshock or..sudden thrusts.

It has been proposedto employ as. substitute bonds ,for the vitried orceramic bond, materials such as rubber, shellac, sodium silicate,l

natural and synthetic resins and the like.l

In producing anabrasive disc or wheel, aside fromrthexproblems of chbice of bond, there is also the'zcessity of controlling. the ratio of bonding material to abrasive material, and it is also highly desirable that, in Icertain forms-"of their most eiiective cutting edges are presented 1 at the abradingsurface and thus are,brought into contact with the/work more emciently; the` provision oi' an improved method of manui'acil 1 turing abrasive discs, wheels and the like in which the-productionof the abrasive article `may be carried out on existing sandpaper, type of equipment, with the subsequent conveniencefof shortening the required time i'or'producing yvarious sizes-of'abrasive wheels and discs.

A further advantage of this invention resides in that, as distinguished from the molding proc- .ess of making `abrasive discs and wheels, which requires that the abrasive grit and bonding material be mixed in the proper ratio, then molded, then heatedgand therefore requiring each separate size of wheel or batch to be handled completely individually from the beginning to the end of the entire fabrication process, the present invention permits of the carrying out of a substantially continuous process 'similar to theA manufacture of sandpaper and that continuous lengths of the material'may be stored in drums or rolls from which the'desired width of strip may bev cut which is to determine the ultimate thickness of the wheel, itbeing assured at alltimes that the ratio of abrasive material to .bondingmaterial will remain substantially uniform throughout the particular wheel or disc structure which it is desired to form. v

The present invention alsopermitsl of the.

manufacture ofy the basic abrasive material o n standard sandpaper equipment and that this material may, after having been prepared, be

. preserved in stabilized form for use in manuprocessand articles'made therefrom known to' us considerable waste occurs in that the discs abrasive grains to the action of an electrical'eldfor the purpose of attaining the desired orientation of such particles; the invention further has as one Vof its objects the improved method of and apparatus for subjecting the abrasive grains during the ight by gravity to the sheet to the effect of an -electrical eld, preferably of the electrostatic type, for aligning the particles with the lines of force of the eld, which for convenience lie substantially parallel with the surface of the abrasive-sheet, thus orienting the grains in the must be cut from a standard made piece of sandpaper, and the portion thus made and not used must be thrown away. The present invention distinguishes from such process in that there is substantially no waste of abrasive material which is attendant upon any dieing to suggested. J

The present invention also has as one of its out process, hitherobjects the provision` of an improved method of producing a flexible abrasive article and the resultant article so that,` asdesired, the manufacturer. may produce an abrasive article of the desired degree of flexibility, and, at the same time, have a substantially homogeneous structure with a substantially continuous abrading surface.

The present invention also contemplates the employment therein and for the production of the abrasive article of a new process of orienting the abrasive grains so that their sharper points will be presented at the abrading surface.A In ordinary sandpaper the abrasive grains are depositedl on the adhesive coated sheet by gravity and as a result lie in haphazard fashion in the adhesive. s

In the presentv invention it is desirable that the abrasive grains be oriented so' as to present the longitudinal aires of the individual particles in a position substantially parallel with the plane of the sheet and substantially perpendicular to the margins thereof so that when the abrasive article is formed from a sheet of abrasive material 4made according to this invention, to form an abrasive disc, the sharper points of the grains will be presented at the margins at each of the convolutions of the disc.

This orientation of' the grains vmay be conveniently accomplished by the action of yan electrical field, and it is therefore one of the further objects of this invention to provide an improved method 4of and apparatus for subjecting the proper desired manner as they are deposited thereon.

This invention also contemplates the improved method of incorporating the grit particles `in an' 'adhesive in yplastic form, andA while the-same is deposited together with the grit on a exible backing, subjecting the incorporated grit and adhesive to the action of an electrical field for aligning the particles and orienting the same in the desired manner.

The method involved in the present inventionI may becarried out in a number of alternative steps, depending upon the form and characteristics 'as to ilexibility and denseness which it is desired'to impart to the nished article.

A preferred method of producing the abrasive article of this invention includes the selection of a fabric, preferably paper, of a desired yand suitable Weight, coating this paper with a bonding `rnaterialand a suitable grit. For our purposes,

we prefer to employ a waterproof bond, and, for example, this may be any of the bonds described and claimed in the patents to Okie 1,565,- 027, 1,565,028, 1,635,801, Carlton 1,775,631, 1,736,- 964.

This paper thus coated with a waterproofbond and a suitable grit may be of the same characteristics as the waterproof sandpaper now known to the trade as Wetordry.

The coated fabric, preferably paper, having the -grit contained in the adhesive layer may be provided with a light or heavy sizing coat, depending on the use towhich the material is to be applied, though in most` instances a sizing coat may be omitted. A

After the bond and adhesive or grit have been applied, the material is then festooned for a sufcientI period of time to dry or partially s olidify the adhesive. It is preferable that the adhesive be not set to its nal condition at this time but to aid in handling the adhesive should be dried to a degree which will prevent accidental displacement of the grit.

The abrasive sheet thus formed may be rolled linto what are known as Jumbo rolls and may be stored until required for slitting into suitable Widths. When it is desired to complete a grinding disc with this material the same may be slit to any desired width which is to be the depth of the disc or wheel and then'wound into rolls of the required diameter. Owing to the fact that :theadhesive material is not entirely set when the sheet is Wound into a roll, thedisc or wheel thus formed may be placed in an (oven vfor further drying and for completely settingup the bond.

By regulating the tension of the strip of abrasive material Aas it is wound into disc-like form the compactness and resultant flexibility of the nal product may be desirably controlled.

Itvwilll be understood, of course, that the resultant flexibility of the article is more or less dependent upon the type of adhesive employed', and that by controlling the flexibility of the adhejsive and the tension upon winding the ultimate n flexibility of the article may be regulated. As'to the waterproof qualities of the article, excellentI results may be obtained by employing ,any of the in. e l

In the actual finished disc material thus produced particularly where the sstrip of adhesive material is relatively loosely wound to form a disc, the convolutions thereof will afford clearance spaces, though they may at numerous points be adhering together by virtue of the adjacent layers of the adhesive.' In-the actual finished article we thus are able toproduce an abrading surface which has sufficient exibility as to binder land composite to facilitate surface sanding, as it binders disclosed in the patents mentioned llere-` desirable flexibility and an efficient cuttingv surface.

In instances w here it is desired to make a solid wheel, that is, a relatively inflexible Wheel orA disc, it may be desirable to cement the laminations, layers or convolutions, as they may be termed, andthis'may be accomplished by interposing a sizing coat .as the strip is wound into the disc form. It also may be desirable in some instances 'to apply the sizing material in a relatively heavy coatimg and to subject the article to heat for causing the coating to flow, and thus relatively intimately connect adjacent layers of the abrasive material. v

This operation may also be accomplished when the disc is wound by immersing the same in a bath of adhesive'size to permit the adhesive material to now by capillary action between the laminations or convolutions of the disc.

One of the important factors which effect the 'adhesive and abrasive coatings to both sides of the backing.

In selecting an adhesive material, we have obtained excellent results with .adhesives formed yas composite materials from Bakelite, that is,

lphenol and formaldehyde. .and other synthetic resin binders, rubber, shellac and the like, it being understood that these materials may be made into a liquid adhesiveV and can be further molded or softened by subsequent flowing under heat in such manner that a thorough setting or curing of the adhesive is accomplished without detracting from the flexibility thereof.

One example of an adhesive which is suitable for our purposev is lthat substantially according to the following formula:

` l y Parts Bakelite resin I 4 Thinner (denatured alcohol)- 1 This composition is agitated very thoroughly until a creamy fluid possessing some tackiness is produced. 'This adhesive is then applied to the sheet which then receives the abrasivematerial.

In fthe case of a Bakelite resinous material,

the adhesive is dried after having received themine/ral either on the racks or festoonsor at. some other point in the production of the. abrasive strip, and we prefer to employ temperatures ranging from normal atmospheric room teme -perature to approximately 140 degrees Fahrenheit, depending on the length of time of drying. In this drying operation the temperature is maintained at such a point that the thinner or solvent only will be driven olf and thus na appreciable hardening or solidifying reaction takes place in the resin at this time. -When the strips are coated with this material together with a binder, heat treatedas set out above and thenv wound into discs or wheels,- they may be further subjected 'to heat which causes a flowing of'v the resinous binder and thus sufficiently unites the several convolutions or larninations of the wheel.v Of. course, if it is desired to make a substantially rigid wheelin this'mannensame flexibility when the disc is not of the solid type Vhesive be controlled to produce the most-desirable this ratio throughout the disc be maintained. By

the `abrasive article of this invention and the method of manufacturing the same, we are enabled to attain a high degree of efficiency in cutting operationsof the disc and to give tothe abrasive article a substantially uniform effective abrasive surface throughout, so that as the same becomes worn in service it yet renders the same efficient cutting and/or abrading or polishing functions. I It will be understood, of course, that dependent upon the desired characteristics of the finished product, wemay employ fine, medium or coarse grits and that, correspondingly', the thickness of paper or other fabric employed and the ratiol of adhesive to grito'r abrasive particles must be controlled in each instance to thedelv sired degree. In certain instanceswel 'applied may be tightly wound and alsor subjected to pressure as Well as heat subsequently.

When employing'a synthetic resinous material such as a Bakelite resin, the same is thinned with a suitable thinner .and coated on the sheet in the same manner as that employedin conventionally forming sandpaper. The grit is then applied as quickly after the binder application as may be practicable. The thinners are evaporated at normal temperatures, andthe bond l thereupon solidifies to the consistency of a coating results and also that the uniformity of varnish partially dried but tack free.

The abrasive article in this condition may thenA be stored in large rolls and cut or slit into ribbon disc portions as required.

In order to insure flexibility of the abrasive article during handling, it is preferred that the rolls be stored in a humid atmosphere, so that the article will bev possessed of flexibility during the heatingoperation. K .After the 4abrasive material is cut and formed -into ribbon discs, the bond may be toughened by further heat treatmentat, say, 180 to 185 degrees Fahrenheit for approximately fifteen minutes,

which' produces a: exible consistency -and is.

- hard bond in which there .is substantially no l -fieinbility' in the binder coat itself. Where a flexible binding coat is desired, a proper regulation of the temperatures and employment of suitable modifiers in the` Bakelite resin will give satisfactory results.

It will be understood that the preference to storing the abrasive in large rolls, jumbo rolls, as they are called, is that sometimes it is diflicult to synchronize the heating operation with the drying festoons, and for some purposes it'is preferred that the abrasive sheet as it is formed be placed in Jumbo rolls so that it may be slit tothe desire'd Widths `as required.

In connection with the foregoing formula we have secured a flexible abrasive strip to be Wound into a disc or wheel shape by employing a Bakelite material which does not produce a complete grit by an electrical field or other electrical action, such as by an electrostatic field, in such a manner that the grits will become orientedA with their major axes parallel to the surface of the sheet and perpendicular' to the abrading surface, particularly where the grits are placed so that their major axes are perpendicular to the v margins of the strip from which the wheel is Wound. We shall describe ,such a. process ofv in whichtype Such-as is disclosed in the patents to Okie hereinabove referred to, and` we have also employed as a binder the material disclosed in theV application of Carlton and 660,319.

Where rubber, shellac or synthetic resins other than Bakelite are employed, we also prefer to heat treat the same in the final setting or, if necessary after first applying the binder to the strip which is to be later wound into the disc form. With rubber, sulphur is added in desired amount to the adhesive material so that the vulcanization of the binder takes place in the heating step. v

Under some circumstances, in order. to prevent Oakes, Serial No.

starving of the bond between ythe grit and the` sheet, it is desirable to applysizing coat to the back of the sheet, and this may be done during the winding ofthe sheet or after the original process of making the sheet simultaneously with the application of the' adhesive and grit.

The outstanding advantages of the present invention, particularly Where the same is wound `into a roll to form a disc orwheel, reside inthat we are enabled to produce a laminated abrasive structure in which the abrading surface presents a more definite and more uniform porosity due `to the laminations and due to the spot contacting of the adhesive on one layer with the adjacent layer, and thus producing a greater pro portion of voids than is possible or obtainable Where' abrasive grit and a bond are molded even l where equal ratios of bond to grit are employed.

Our 'invention also produces a laminated abrasive structure having an increased strength due to the incorporation therein of the coated backing of fabric such as paper or cloth, whichadds to the strength of the entire wheel-making the same less 'brittle and more flexible and permitting of thin. ner wheels to be prepared than by any other prior method known to us.

Anotherv distinct advantage of our invention resides in the fact that the mineral grits, owing Figure 1 is a schematic view of an apparatus which may be employed for producing the abrasive article of this invention.

Figure 1a is a schematic view of a slitting and winding apparatus which may be used with the apparatus shown in Figure l.

Figure 2 is a plan view of an abrasive disc m'ade according to this invention.

Figure 3 is a transverse sectional view taken on the line '3 3 of Figure 2 looking in the direction indicated by the arrows. i

Figure 4 is an enlarged transverse sectional view taken on the line 3 3 of Figure 2 looking in the direction indicated by the arrows.

Figure 5 is a schematic view of apparatusfor coating one or both sides of the abrasive article.

`Figures 6 and 7 are 'fragmentary sectional views of an alternative form of` an abrasive article made according to this invention.

Figure 8 is a schematic View of lan alternative form `of apparatus for securing orientatior( of the abrasive particles.

Figure 9 is a. view showing Figure 8 from another aspect'.

Figure 1,0 is an elevational schematic view illustrating alternative apparatus. for carrying out the step of orientation of the abrasive particles..

Figure 11 is a perspective view of an alternative form of apparatus of this invention.

Figure 12 is an elevational view of a still further modified form of the invention.

Figure 13 is an enlarged sectional view of a the apparatus of sheet illustrating the alignment of the abrasive Referring `now more particularly to the drawings, and first to Figure 1,-thereis shown a roll y, neath a hopper to their elongated nature, may be oriented on".

the abrading device so .that their sharp points are presented at the abrading surface. For some purposes it is desirable to deposit the abrasive of fabric such as paper or cloth 5, from which lthe web 6 is unwound over an idler roller 1, to receive from a. coating roll 8 a layer of the adhesive material delivered by the series of feed rolls 9 from a tank III. The web 6 is fcdvbe- Il from which is supplied a quantity of comminuted abrasive v.materiall I 2 by gravity, which may be suitably regulated in any desired manner to determine the thickness of the grit layer. The positioning of the abrasive material may be controlled at this-point by the use of-electrical orienting apparatus as shown in Figure 8 and hereafter more fully described. The

sheet or web 6 is then trained over a roll I3 and reflexively bent upon itself bya roll I4, some of the/grit in excess of that desired being removed by falling by gravity into a container I5. The web 6 with the layer of grit secured thereto by an'adhesve, waterproof if desired, is then fed into a drying room or oven IB, and arranged in festoons I1 by the provision 'of rolls I8 in said drying room.

The temperature of the drying` room is r'nai'n tained at a degree which will only partially set the adhesive suiiiciently to .permit handling of the abrasive coated strip or sheet indicated at 6a as it leaves the)` drying room. At this'point Figure 1 shows the sheet as broken, indicated at I9, inasmuch as it may be desired to store the resultant product at this point before continuing the same to the slitting apparatus. However, if it is desired to have a continuous making process, then the sheet or web is supplied to slitting apparatus represented :by the cutting knives 20. as shown in Figure la. These knives may be arranged at any convenient distance apart, depending on the width or thickness of the strip to be cut and ultimately .wound into Ythe abrasive disc.

.From the slitting apparatus-the several resultant strips of abrasive sheet material may be fed to a mandril; I, on which they may be wound into the final abrasive Vdisc elements producing the articles such as shown in Figures 2, 3 and 4.. It will be understood that while the strip shown f at 6b in Figures 1 and 1a is wound with the abrasive coated side outwardly, thus leaving an outer abrasive coatedwsurface exposed at the. last convolution, the disc may be as readily wound inthe opposite direction so that the abrasive coated surface of each lamination will-be presented inwardly. `Inasmuch as these -discs are intended to grind on one`of their side faces, and

either way desired.

40- as a' substantially continuous abrasive coated Isurface is thus afforded, the discs may be wound It is also to be understood'that by placing-the .K

strip 6b under more or less tension as desired,

a tighter 'or looser wound disc maybe obtained.

When the abrasive material is deposited by gravity yas shown in Figure 1,;'it willbe understood that` the abrasive grains will fbe largely lying haphazard on the abrasive surface, though a large number of them will contact of the freshly coat surfacewith the roll I4 so that .whemth strip 6b is wound into a roll to'form the disc the grains will 'be knocked down in such a manner that their sharper points e oriented by the.

will, as the disc is employed in grinding or polishing the surface, be brought 'against the surface of the work. However, to insure that the majority of the grits will be so oriented, we have provided methodscand apparatus for so orienting the grains which will be described more vfully hereinafter.

Figures 2, 3 and 4 illustrate a disc made according to this invention, wherein thediscis composed o f a pluralityof convolutions 22 of abrasive coated material alfording a laminated abrasive structure.' The laminations are held together by the adhesive' material establishing contact on one convolution with the back surface `epi the adjacent convolution so `that a structure` somewhat similar to Figure 4 will be obtained, the innermost convolution 22a having its coating 23 of adhesive material contacting yat a plurality of points, indicated at 24--24 with the, back i surface 25 of the immediately adjacent convolution 26. Thus the 'abrasive grains indicated atv 21 :in the layer of adhesive 23 are substantially embedded therein with Vtheir major axes and thus their sharper cutting points presented toward the margins of the laminations.- In this way a substantially continuous abrading .surface indicated at 28 on the surface of the disc is thus' provided.- It will be understoodthat care must be -exercisedfthat the proper weight`of paper Vwith regard to abrasive and adhesive be selected.

the backing 29 may be of a rigid material and the disc likewise cemented thereto.

InFigure 4, it will be understood, of course,

that the thicknesses of the convolutions and ylayers of grit and adhesive have been greatly exaggerated in size, although it is conceivable that one might produce an abrasive article hav 'ing convolutions whose thicknesses are as great as those shown in Figure .4. fHowever, in the ordinary form of the invention for employment in standard surface grinding the disc is made up of a sheet not substantially greater in thickness than a sheet of ordinary sandpaper, thus lending to the nal product a desired degree of flexibility.

t will be observedthat in some instances it I may be desirable to provide grooves in the abrade ing surface 28, these grooves being ,shown at 3l in Figures 2 and 3. It will also be noted that the grooves 3| are preferably of greater depths at their inner ends toward uthe axis of the disc,

than at their outer ends adjacent to theperiph ery of the disc. 'Ihese grooves maybe formed inf/'the disc after the fabrication of' theI same inasmuch as forming the grooves in the' strip prior to nally windingwould require consider-E able cae in aligning the notches in each convolution from which these grooves are formed.`

AThe disc thus formed contains a number of voids -whichare afforded by virtue of the grit particles themselves holding the .laminatlons apart and Iby the vacant'places indicated at 25u,y

- where the glue or other adhesive does not coming operation may be accomplished by the apparatus shown in Figure 5.

After making a double coated strip, it is then pletely ll the spaces between 'the convolutions. Thus the abrasive article quickly cleans itself as it works and clogging or loading of the article is practically impossible.

We have found that a satisfactory grinding and polishing wheel may be constructed by methods disclosed herein, and in one form of the invention, which is illustrated in Figures 6 and 7, we apply a coating of adhesive material containing an abrasive to both sides of the strip forming the flexible abrasive article. This coat wound loosely into a conflgurationsubstantially like Athat shown in Figures 6 and "1;,h The thus wound material is then thoroughly cured and dried. After curingthe disc-like structure thenl afforded is cemented to the cloth backing in such a manneras to preserve the open or spaced convoluted structure as shown. The polishing compound, which may be' according to vthe for` mula appearing below, is thenjforced into the spaces between `the layers and when completely filled with polish the disc is then allowed to set .for sufficient time to solidify the polish base.

This drying time, we find to give best results by subjecting the article to a drying temperature for approximately forty-eight hours.

A satisfactory formula which we have employed for the purpose of compounding the polishing material may be as follows:

y Grams Nitro base thinned to 50% solids `200 Dibutyl phthalate. 4.0 400 silicon carbide v 40.0 Tripoli 150.0 -Borax 16.0 Erkalin 4.0

From the foregoing it will be observed that we produce a convoluted structure indicated generally at 50, composed of the laminations of thev It will be understood that it is highly desirable that the comminuted abrasive material be disposed on the strip or sheet in such manner that the individual grits will have their major axes preferably lying parallel with the surface of the sheet, and, where the sheet is to be wound later to form a disc which marginally exposes an edge of the sheet for forming the abrasive surface, that the grits be perpiendicular to the longitudinal margins of the shee While orientation of the gritsk'with their major axes parallel with the surface offthe sheet and substantially perpendicular to the edges thereof, may be more or less accomplished in simple gravity deposition of the grits on the adhesive coatedsheet, a positive orientation of the individual grains may be accomplished by electrical action, that is to say, the grits may be deposited perpendicular or substantially on the sheet in the presence of an electrical field, for exampleelectrostatic, or if the grit particles are of a magnetically responsive nature then in the presence of an electro-magnetic, field. Grits deposited in thepresence of such an electrical field will be icaused to align themselves with the lines of force of the electro-magnetic or electro static field as the casemay be.

For most abrasive articles an electrostatic field will perform the functioninasmuchA as most of the grit particles commonly employed in the abrasive arts are of a non-magnetic character and are non-conductors and practically all will respond to the force of an electrostatic field.

Referring specifically to Figure 5, we provide a suitable backing for carrier strip 63 whichreceives coats o f adhesive material `on both sides thereof from a suitable tank 64, the strip being conducted upwardly between two chambers 6,5 and 66 and then conducted through edge guide rollers 61. f

In the chambers 65 and 66 thererare provided electrodes 68 and 69 of preferably negative polarity, the sheet being itself of a conductive nature and connected to the positive side of a source of electric motive force indicated at 10.

The apparatus receives grit from hoppers 1| and 12` which isagitated in the form 0f clouds hopper 84,

within the chambers 65 andv 66 by air blasts introduced at the nozzles 13 and 14. l

- 'I'he apparatus shown in Figure 5 is similar to that shown in the patent to Smyser 1,788,600, and serves to illustrate one apparatus for carrying out the double coating simultaneously. ,This form of the apparatus does not, however, produce orientation of the grit particles with their major 4axes parallel to the plane of the sheet, and reference will be made hereinafter to forms of the invention including apparatus for this purpose.

It will be understoodthat the sheet may be coated on both sides by running Iit twice through .either a gravity coating apparatus or any of the apparatus shown inthe other figures of. the drawings.

As herein pointed out, it is desirable to orient the grit particles so'that they will lie'with their major axes substantially parallel to the surface to be coated, and sharp points at the same becomes worn in use as an abrading disc.

This orientation of the particles uniformly on the sheet is also of utility in the manufacture f mineral coated shingles wherein it is desirable that the particles of be deposited so that a minimum number of the mineral granules is required to cover a given area of the asphaltum sheet or' other material from which the carrier made.

`We have illustrated herein a number of ways in which this may be accomplished which are all included in the disclosures ofl Figures 8 to 12,

indicated by the hopper 4 With reference first to Figures-8 and,9, we

have employed a backing 16, of suitablematerial which receives a face of the horizontal flight thereof shown in Figure 8, this coating being applied from a set of adhesive distributing or applying rollers 11, 18 and 19, the latter taking up adhesive from a tank 80.4 and the backing is then 'propelled to the left as viewed in Figure 8 between electrodes forming an electrostatic field.

These electrodes, welhave found, may conveniently comprise a pair of circular disc-like plates flight of paper 16 passes at a desired rate of speed.' Other forms of the plate electrodes may be employed, but we have found that this type produces a uniform field and highly satisfactory performance. v

Above the flight 16, and at a distance sufficiently remote from the electrodes so as to be substantially unaffected thereby, we provide a which may contain abrasive grains of the desired an abrasive grain or pulvule of a slivery character that is somewhat elongated, will give highly desirable results as to orientation, though it will be understood that it is not necessary that this type of pulverulent material be employed in order to attain the results of this invention. Practically all of the grits employed in the abrasive industry today are characterized by having a major and a minor axis so that they become responsive to the actionfof an electrical field when introduced into the presence of the same.

These gritsv are deposited by gravity from a ey will thus present their. edges ofthe strip as the mineral, granules or the like,

or backing of the shingle isl coating/'von the upper sur' This yadhesive layer is indicated at 8| 82 and 83,' between which -the horizontal size. We find thatfor our apparatus hopper 84 havingl a suitable controlling gate 85 over a distributing roller 83 so that they fall in. a; substantially continuous stream 81 toward the adhesive surface 8l, passing between the electrodes 82 andi 83 in their path to the adhesive.l

surface.

We have discovered that a static electrical field solely, that is to say, without outside influ- A source of electromotive force, preferably of relatively high voltage, is provided. The voltage employed in one arrangement of the electrodes was about 105 kilovolts and in employing this voltage the plates or electrodes were spaced about 5.5 inches apart in air. This arrangement served to maintain a constant electrical potential gradient of approximately 19 kilovolts per inch between the electrodes.

In correcting for uneven distribution, the electrical center of thel sourceof difference of .potential is grounded as indicated at 84a in Figure 9, and the source composed of two units 85a and 88a is so connected through pole changing switches, 81a, 88, 88 and 30 that the relative polarity of the two plates 82 and 83 forming the electrostatic field was changed at a desiredfrequency.

We have found that, for our purposes, with the plates spaced between 5 and ,6 inches apart in air, the best results .arebbtained by the use of electrical potential gradients of the range of -from 17 to 20 k. v. per inch. We also iind that Where reversal of polarity is resorted to, as in the disclosure in Figure 9, the' optimum of frequency of polarity change or reversal should be in the vicinity of twocycles per second. However, we have found thatA rangesA of from one cycle, per second to four cycles per second produce satisfactory results and that little change was noted in thereby producing satisfactory dis-J tribution and orientation of grit particles on the sheet.

It will be understood that the foregoing dis' closure of values as to voltages, rates of polarity the two electrodes and the backing itself, .this difficulty being eliminated by the form of the electrodes, so that the major value and resultant force of the electrical field is retained.

In the more convenient form of the invention shown in Figure 9, successful results will be ob' tained by employing disc-like electrodes 82 and 83 of a diameter of about 8 inches, and with the opposed faces of the electrodessubstantially parallel toeach other.

A further form of apparatus which we may employ for carrying out this method of deposition is illustrated in Figure 10 wherein the strip, sheet or web of Figure 1 is` indicated at 33, the one side of said sheet being provided with a layer 34 of adhesive material, preferably waterproof in its characteristics, though, as will be obvious, this layer of adhesive may be of the-- ordinary glue bond type employed in the sandaier industry fory non-waterproof abrasive arc es.

The sheet 33 is caused to travel in a vsubstantlally horizontal plane below a hopper 35 and between the electrodes 36 and 31 of anelectrical ileld, the electrodes 36 and 31 being connected'to an appropriate source of electrical potential of the required value. In actual practice what are known as high voltages may be required, though it will be understogd that the dierence of potential to beemployed is subject to variation as desired for accomplishing the ultimate desired action., l 1 For the'purposecf the present disclosure the electrodes 36 and 31 form part of an electrostatic eld, that is.to say, a eld/in which a constant stress is set up but in which relatively small currents flow. Suchan electrical field will "be established betweentheelectrodes 33 and 31 indicated generally by the linesA of force 3E. Thlsffield is set up between the electrodes 36 and 31 above the sheet 33 and belowl the hopper 35, and the field strength is regulatedY to such yan extent-i as to act upon the abrasive particles as they areA fed from the hopper 35.

39 but some of them are shown enlarged at 49 change, and size of and distance between the plates is all subject to variation to suit the particular conditions and results to be attained thereby.

We have also found that with diierent types of abrasive grains different results lwere obtained. For example,y with siliconv carbide in some arrangements of the plates compensation y had to be made for diiculty encountered due to the high conductivity of silicon carbide, where as with 'certain other grit particles these diiliculties were not found present, such, for exam-.- ple, as in the use of int.

From the foregoing it will be understoodthat the electrostatic field established either con-l stantly or intermittently together with reversal of polarity between the plates 82 and 83 affects the grit particles, as they enter the electricalj eld, to bring them int.; axial alignment with the lines .of force of this ileld. No appreciable assume as they fall by gravity through the U electrostatic field. It will be understood that should the electrostatic field be of great enough strength, theA particles issuing from the right hand end as s how in Figure 10, would be caused to orienr themselves with their major axes parallel with .the lines of force of the electrostatic field and be projected by that `iield from one of the electrodes toward the other thereof.y Therefore, by regulating the electrostatic field tothe desired Aoptimum the .particles will be caused merely to flatten out, and while they may, under these circumstances bei `caused to travel along -Ythe lines of force of the eld, the force of gravity will tend to overcome their flight toward the op positely charged electrode and they will fally upon the layer or adhesive, assuming positions substantially as 'shown in Figure l0, and indi-- cated at 4! This orientation is more uniformly' accomplished, however,-in the form of the apparatus` shown in Figures 8A and 9.

Inasmuch as the particles'ofv abrasive mate difhculty is found to exist by the presence of the backing material 16 inthe field, which would ordinarily be assumed' 'to occur. due to the se'tting up of extraneous electrostatic elds between rial as they leave the hopper adjacent to the electrode .36, may in a large number .of instances never reach the sheet, due to their attraction to the`other electrode, we `provvide .a movablepartition 42 in the hopper, which-may be adjusted transversely of the longitudinal axis of thesheet The' abrasive particles areshown as a cloud so that the length of the slot in the bottom of the hopper may be varied to cause the grit particles to issue through only a portion of said slot. A suitable handle properly insulated indisume positions perpendicular to the sheet, the

electrodes 36 and 31 may be supplemented by auxiliary electrodes 44 and 45 which may have a voltage regulated (by means not shown) to exert a sufficient electrostatic field effect or action to prevent the particles from taking undesirable positions just as they strike the" glue. If desired, this auxiliary eld whose lines of force are indicated at 45, may be.extended a desired distance beyond the point` of actual deposition so that it vwill function for a period of time after the sheet has moved beyond the effect of the major electrostatic field.

Inasmuch as the poles or electrodes 36 and -44 and 31 and 45 are of like signs, there will be no tendency to set up extraneous electrostatic fields between these electrodes other than substantially ineffective electrostatic or electro-magnetic elds, as the case may be, due to difference in actual potential ofthe tworfields '38 and 46. In any event, inasmuch as the electrostatic elds employed have their lines of force substantially parallel, the effect of "any extraneous eld set up between the electrodes 36 and 44 and 31 and 45 should be substantially negligible in disturbing the desired deposition and orientation of the particles on the sheet.

An illustration of one arrangement of the electrodes whichwill set up the desired electrical action is shown in Figure 11 in perspective. Of course in some instances it may be desired to eliminate the secondary electrostatic field 49 and by proper control of the moving partition 42 the desired results may be attained as to ultimate effect of the field on the grit particles.

Figure 11 serves to illustrate a further modied form of the hopper. In this form the hopper is of a general V-shape cross section and the bottom thereof being open is provided with a tapering slot indicated at 41. The slot is of greater dimensions at one end than at the other end so that by proper flow from a suitable opening 59 provided in the bottom of the hopper. A

As' the incorporated grit and adhesive material flow from the hopper onto the sheet 33, the mass is subjected to the force of an electrostatic field .62 set up between the electrodes 60 and 6| thus i orienting the particles of grit contained in the adhesive according to their electrical responsiveness to such-a eld, that is to say, the grits having major and minor axes, as hereinbefore pointed out, will under the influence of the electrostatic field become aligned with the lines of force 62 shown in Figure 12, while in the glue or other adhesive and thus be carried bythe glue or ad- ,hesive on to the sheet where they will be deposited i Y sheet such as that shown in Figure 13 is illustrated having two or more layers 4 la of grit material and adhesive material deposited thereon.

In order to make clear tothose skilled in the art the basic principles involved in employing the electrostatic field for the purposes of the present invention, Figures 14 toV 18 have been incorporated in this disclosure showing the various steps in development' to obtain the optimum ofv results in deposition, distribution and positioning of the hopper the particles of abrasive acted upon by one'of the electrodes and tending to be projected toward the other thereof would be counteraeted by the tapering slot inthe hopper, thus preventing piling up of the abrasive grit at one margin of the sheet.

It will also be understood that by regulating the height of the'hopper 46a from the sheet that different effects may be obtained to the point where the desired-orientation and deposition of the grit is attained.

The electrodes 44 and 45 may be employed in Figure 11 as in Figure 1Q if that be found necessary under the circumstances.

Referring now to Figure 12, the apparatus here shown discloses a -hopper 58 into which the orientation of the abrasive particles.

It will be understood that these Figures 14 4to 18 all illustrate methodsfor producing deposition, distribution and orientation, but that some profrom the following description. A.

On reference to Figure 14, a pair of electrodes, preferably'in the form of circular discs 92 and 93 are employed, one of these discs being connected duce better results than others as will appear to the positive side, s uch as at 94, of a source of difference of electrical potential and the other disc being connected to the negative side or ground as the case may be. f -A relatively high difference of electrical potential was thus impressed on the two plates establishing an electrostatic field betweenv them, into which abrasive particles 96 were introduced, either by gravity as shown in Figure 14, or by any other suitable means, so as to produce a'stream of the particlesv as they enter the electrostatic field established between the plates 92 and 93.

This pair of substantially circular metal plates are made about 8 inches in diameter and provided with curved edges indicated at 91 and 98, thus preventing excessive concentration'of the field at the edges of the platesl thereby. reducing the possibility of sparking between the plates. These electrode plates were spaced about 5.5 inches apart in air and were connected to a source of electromotive force approximately 105 kilovolts, so that 'a `substantially constant electrical potential range of about 19 kilovolts per inch was comminuted abrasive material andan adhesive material in plastic form -are introduced. 'I'he hopper may be suitably heated to maintain the adhesive material in a liquid state so that it will maintained between them.

The mineral pulverized `material (in one instance grade silicon carbide) was deposited so as to fall in a stream between the two plates 92 and 93.

When either of the plates is grounded, the

mineral stream which was originally at ground lpotential is deflected toward the ungroundpd plate, so that if an adhesively coated strip was introduced between the plates 92 and 93, while orientation of the particles transversely of the i strip was attained, `yet deposit of mineral would take place in excess at one edge over that at ane other edge of the strip.

Y To overcome this uneven distribution of particles, the plates may be connected to the lsource of potential through a reversing switch or pole plate to ground and to high potential, in other words, supply an alternating voltage to said plates. l

' Onemanner of accomplishing this is vdisclosed changer which alternately serves to connect each in Figure 15, in which the plates 92a and lla are l connectedthrough a pole changing apparatus lla to a source of relatively high electrical potential,

The stream of mineral at low, frequencies of reversal of polarity moved from one plate to the other following the reversals of polarity of electhem is connected to one of the sources of dif.

ference ofpotential indicated at 1b and the the me whose gradient is aboutie k. aser.

finch. There is in such circumstances apparentl ly no tendency for the mineral particlesto mi"A grate toward the zone of high gradient, Vand the general dispersion and orientation ofthe par-V ticles is not materially interferedwith and not materially different from that where the Yplates are substntlallycparallel. 'and the potential gradient therefore substantially uniform.

Successful results may be obtainedl withany of the foregoing arrangements, by the 'employmentv of an abrasive grit of agrade 11/2 flint, preferably of a splintery nature.

We find that a higher electricalpotential gra- I, I

dient may be maintained without disruptive dis-,- charge or so-called spark-over with flint. for example, than with other grits such as, silicon cari bide, inasmuch as in the same air space potential gradient and with the same relative quantity of grit introduced thereinto, the conductivity ofv silicon carbide, being higher than that of int, tends to produce an increased tendency to sparkc over or brush v discharge, as itv is sometimes 1 termed, and care must in somecases be exer- '25 .cised to prevent the formation ouf a conducting Vpath. between the plates.

A method of overcoming this diflicultyfor cerlates 91d and SM1-were arother tothe other source indicated at IIb, thev ranged on opposit sides of insulating plates |02- electrical centre of the sources indicated at Figure i6 being grounded as yat 800. in this arrangement the main mineral stream becomes divided into two separate streamsy each of which tended to flow toward one of theV platesthereby leaving a low mineral concentration in the space midway between the plates.

From the foregoing Figures 14, 15 and 16 it will be observed thatwe are enabled by adjustments and variations infthe intensity of the electrical value with certain minerals. 'there is no marked tain purposes is shown in Figures 18 and 18a, l

wherein the two dierence in the action of the/electrostatic field with other minerals. and we have found this ar' rangement of Figures i8 and 18a to be of value in increasing the activity` of flint, but of much less perceptible value in increasing the activityj held and by its polarity and/or periodicity vof change and by other adjustments, to regulate what will happen tothe mineral grits as they are introduced into the electrical field. Thus where it is Adesirable that the grits 'oe more heavily deposited at one portion of the adhesive coating backingthan at another portion'this can be regulated to a desired degree as required.

Should it be desired to prevent excess deposition of the grit in predetermined areas, then the form of the invention shown in Figure 9 and c hereinabove described may be employed. For

of silicon carbide, inasmuch as spark-over or brush discharge sometimes occurs which causes the greater part of theapplied voltageto bebuilt up across the insulation.

lTheobserved motion of the particles was subtion, but, as pointed out in the case of some abrasive particles, an increased attivit? without a resultant brush tlischargewA observed. lThe plates also serve as a ineans to echanically conin the plates.

the purpose of manufacturing abrasive discs as dieiltcsedherein this form of the invention finds u In Figures 17 and 17a, a further alternative ar- Figure l? 4being a view looking down on the plates, the backing element being indicated at In Figures 17 and 1'Za.we disclose the elec i `trodes arranged in convergent planes so that.

some portions of the surfacesof the'discs-were `closer together than otherv portions. the Inu"-Y rangement of the electrode plates is disclosed,

Referring now more-particularly to the form observed that here may be provided a form' ofthe apparatus wherein the-electrode plates 'are alternatelyV connected to ground. Inthlsform ofthe invention the plates indicated at IM andfllii` j stantially the same with or without the insula- 45 of the invention shown .in Figure 19, it will'be are connected byconductors i andllil to the t negative and positive sides, respectively, of sources of electrical difference of potential Illay -nected in series as shown.

. A grounding-switch is provided indicated ,gen-z? c5 swltchingmembers Hl and Hl serving to a'ipose being to further allow for adlustment in distribution ofthe grit particles.

The.. ,grit particles entering 'this electrostatid' field are subjected to a variation inpotential gradient from 17 k. v. per'inch to 24 k. .v. per' ternateiy connect lwith groun. e

Et will beiseen from the form of the inventiony Ydisclosed in-Figure 19 that by" th/alternative inch, or. any other variation 'of the electrical po- -'tential gradient.- depending upn the voltages" employed, size ofplat, etc.-

-rne stream of minerai-1sauwed toren into "5- .70' grounding of the plates lIM and Inl/{theori'enting force-exerted bn-vtheparticleis uniformly maintained by -virtue'ofthe m 'ntenance'of a constant gradient between the/plates.-rr Dispersion of the particles thus uniformly obtained by the use of the switching arrangement prevents theconductors lili andlill and il. that is, sources'of potential being conthe grit particles on the sheet. l

the bu1k of the particles4 (which, a wm be underf stood, are at ground potential when they pass' into the zone of the plates) from being directed more toone plate than to the other.

The form of the invention shown in Figure 19- operates similarly to the form of the invention shown in Figure 9. 1 Reverting to the form of t e invention disclosed in Figures 8 and 9, the st cture there employed including a reversal of polarity does not include the insulating plates and these, under orf dinary circumstances, are not required.

Under conditions shown vin Figure 14 and With-y out the use of insulation on the plates or between them.- flint particles dropped into the eld whose gradient was 15 k. v. per inch were fairly well oriented on the sheet but the distribution is -not entirely uniform.

An increase in gradient from 15 to 17.5l k. v. per inch resulted in the production of a marked increase in the degree oforientation, but as well increased the inequality of distribution.

With abrasive grains of silicon'carbide a limiv tation of the potential gradientwas required so as' to prevent dielectric breakdown. v

The use of insulation on the plates serves to cause the mineral to be more evenly distributed, but it will be understood that some slight amount of orientation vmust ybe sacriiiced owing to the .slight reduction in the potential gradient caused by the employment of the' insulating plates.

v From the foregoing it wm be observed that by adjustment-oi.l the electrostatic ileld value and/or adjustment of the plates with respect to the ali'` space between them and/or their angularity with respect'to veach other, and/or the periodicity of polarity reversal, we are enabled-to produce desired effects in the orientation add distribution of Where the particles are deposited on shingle material forthe purpose of roonng shingles and the like, it will be observed that by causing them to lie -flat on the adhesively coated sheets, such as van asphaltxm adhesive sheet or the like, the employment of a lesser number of particles cover a given area oi' the shingles is required.

- substantially parallel with theplane'of said backplying an adhesive layer to a surface thereof, and

v:apegarse Certain phases ofthe features of our invention dealing with other vembodiments of the process and the apparatus are claimed in our application backing sheet.

v2. The process of coating `which includes as l steps thereof feeding a substantially continuous and extended length oi carrier or backing and applying an adhesive layer .to a surface thereof, and depositing on said adhesive layer pulverulentI abrasive grit particles of elongated nature in respecto! their major axes under thezinuence of an electricalfield whose linesy of force extend .substantially parallel to the plane of said vbacking and substantially at-rightangles to the 1ongitudinal axis thereof for causing said grit par' ticles to assume positions with their lmajor axes ing and perpendicular to an edge thereof and substantially normal to the effective working surfface of the article tobe made.

3. The.. process of coating which includes as steps thereof feeding a carrierpr backing and apdepositing onsaid adhesive layer a pulverulent abrasive grit'while passing said backing edge f wise through a non-uniiorm-electrical eld e whereby the particles, are subjected to a variation in potentialv gradient-as the backing moves through the ileld, said eld tapering in intensity from one edge toits opposite edge.

* RICHARD PAUL 'CARLTON 'mnoDoaE JOSEPH 

